Middle East Research Journal of Engineering and Technology

ISSN 2789-7737 (Print) | Open Access

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DOI: 10.36348/merjet.2021.v01i01.004 Email: office.kspublisher@gmail.com

Application of Lean Manufacturing Tools and ICT to Increase

Productivity Levels and Reduce Costs in the Brewing Industry in
Ensenada, Baja California, Mexico
Elizabeth Romero Samaniego1*, Juan Gabriel Lopez Hernadez2, Cory Magaña Nava2, José Cupertino Pérez
Murillo3, Rogelio Lopez Rodriguez3, Pedro Alberto Escárcega Zepeda4, Rigoberto Zamora Alarcon5
1
Tecnologico Nacional de Mexico, Tecnologico de Ensenada, Ensenada, Ensenada Baja California, Mexico
2
Centro Bachillerato Tecnologico Agropecuario 146, San Quintín, Baja California, Mexico
3
Facultad de Ingeniería y Negocios, San Quintín, Baja California, Mexico
4
Departamento de Ingeniería Industrial-Metal Mecánica, Tecnológico Nacional de Mexico, Instituto Tecnologico de
Mexicali, Mexicali, Baja California, Mexico
5
Departamento de Ingeniería Industrial, Facultad de Ingeniería, Universidad Autonoma de Baja California, Mexicali,
Baja California, Mexico

Abstract: This investigation was prepared to evaluate productivity levels because in

Research Paper
2018 there were low rates due to inadequate planning in the manufacturing stages of a
brewing industry, located in the city of Ensenada, Baja California, Mexico. Starting in *Corresponding Author:
2019 and 2020, even with the presence of Covid19, productivity rates increased. Said Elizabeth Romero Samaniego
Tecnologico Nacional de
increase in productivity was due to the application of lean manufacturing tools, such as the Mexico, Tecnologico de
Value Flow Map (MFV), Kanban and Kaizen, managing to generate an efficient fluid Ensenada, Ensenada, Ensenada
process, and thereby increasing levels of competitiveness. In addition, an automated Baja California, Mexico
system was used using Information and Communication Technology (ICT) to control time How to cite this paper:
and improve the flow of the production process. With the analysis of the aforementioned Elizabeth R. Samaniego et al.;
tools, the stages of the production lines with the highest incidence of causes that caused, in “Application of Lean
certain manufacturing stages, poor productive performance of personnel and machinery Manufacturing Tools and ICT
were determined, indicating levels less than 50% and thus costs of production increased, to Increase Productivity Levels
generating great concern in the directive, managerial and supervisory personnel. In and Reduce Costs in the
Brewing Industry in Ensenada,
addition to the lean manufacturing analysis, an automated system was designed and
Baja California, Mexico”.
applied, controlled by ICT, to help detect when the process flow was not optimal, Middle East Res J. Eng.
indicating the moments in which the machines performed technical stoppages and stopped Technol, 2021 Nov-Dec 1(1):
the production line. The investigation was carried out in 2020, even with the presence of 28-35.
Covid19, the industry where the analysis was carried out continued operating normally Article History:
with the safety and hygiene protocols. | Submit: 12.11.2021 |
| Accepted: 28.11.2021 |
Keywords: Lean Manufacturing, Productivity, Competitiveness, Brewing Industry, Costs. | Published: 24.12.2021 |
Copyright © 2021 The Author(s): This is an open-access article distributed under the terms of the Creative Commons Attribution 4.0
International License (CC BY-NC 4.0) which permits unrestricted use, distribution, and reproduction in any medium for non-
commercial use provided the original author and source are credited.

and therefore the generation of extra costs. Based on

INTRODUCTION this, continuous improvement activities were
The beer industry is one of the most important developed, with lean manufacturing tools: Kaizen,
in the global economy, which generates a relevant Kanban and Value Flow Map, in conjunction with the
percentage of the Gross Domestic Product (GDP) of the use of ICT coupled to an automated electronic system
countries that are dedicated to this type of industry. In (García J, 2018).
this research, an analysis was made of the presence of
low productivity and quality indices and a large number Lean Manufacturing Tools
of defects in manufactured products (Arrieta J et al., Lean manufacturing is widely applied in
2011). These products had the following defects: (1) industrial processes of any type of industry, and in this
spilled liquid level (beer) product loss and economic research carried out in a brewing industry; three lean
losses, (2) low liquid level (beer) and (3) bottles without manufacturing tools were used, such as the Value Flow
a label. These three defects required work as overtime,
Peer Review Process: The Journal “Middle East Research Journal of Engineering and Technology” abides by a double-blind peer review process such
that the journal does not disclose the identity of the reviewer(s) to the author(s) and does not disclose the identity of the author(s) to the reviewer(s).
28
 Elizabeth R. Samaniego et al.; Middle East Res J. Eng. Technol., Nov-Dec, 2021; 1(1): 28-35

Map, Kanban and Kaizen. Each of the tools used in this
scientific study is explained below (Fontalvo T 2018).
a) Value Flow Map. It is based on a process of
verification of industrial operations, where the
activities of the value chain are evaluated, being a
management tool that helps to quickly detect
variation that causes a problematic situation and
with it defective products.
b) Kanban. This tool had its origin in the Toyota
company installed in Japan in the 1930s, when it
was developed for the analysis of industrial
processes in automotive manufacturing. This tool is
used as a visual method to control the activities of
industrial operations, whether manual or
automated, in order to establish an organization in
an optimal way, with the aim of increasing
productivity and quality levels and increasing the
quantity of products. Manufactured, in addition to
reducing defects and errors.
c) Kaizen. It is based on the development process of
the Deming circle, to make the required
improvements in industrial operations with the
modification or development of new methods,
mechanisms or annual and automated systems, or
the use of new equipment and industrial machinery,
to achieve the goals of increases in quality and
productivity, as well as manufacturing the quantity
of products required for the customer and reducing
or eliminating defects and errors.
The use of the value stream map has the
function of showing the various stages of the industrial
process, to identify each characteristic that generates an
action in each industrial activity. Each characteristic
detected in each stage of the industrial process,
contributes a value that is relevant when carrying out
continuous improvement, and is represented in the
value flow map, to determine the priorities to be
evaluated immediately. Figure 1 shows an illustration of
a value stream map (Gutiérrez H et al., 2013).

Figure 1: Representation of the Value Stream Map for the development of continuous improvement.
Source: https://www.reliableplant.com/value-stream-mapping-31747

The Kanban tool is used in conjunction with problems and thus not generate problematic situations
the Kaizen tool with which industrial operations are in the field of decrease in productivity, quality and
evaluated and the pertinent improvements are made quantity of products that so much worries directive,
with the actions of planning, preparing, verifying and managerial and supervisory personnel (Gómez R,
acting (PEVA Model), meaning the way to act at the 2012).
required moments that support in the solution of
© 2021 Middle East Research Journal of Engineering and Technology | Published by Kuwait Scholars Publisher, Kuwait 29
 Elizabeth R. Samaniego et al.; Middle East Res J. Eng. Technol., Nov-Dec, 2021; 1(1): 28-35

The way to start the activity of analyzing with

the Kanban tool is to observe in detail the flow of
industrial operations, managing to obtain with certainty
a visualization of the functions of each person, as well
as the equipment, machinery and industrial systems that
perform the tasks. industrial operations. Subsequently,
the actions of both people and those of the equipment,
machinery and industrial systems are delimited,
analyzing the times and movements of each activity, to
determine if it is necessary to carry out some type of
improvement, which helps to increase productivity
levels, quality and quantity of manufactured products.
And once the previous stage has been elaborated, the
productivity and quality criteria of each manufactured
product are analyzed, to adequately develop the
required improvements and the improvements are
developed, constantly evaluating them during a certain
period of time, to verify that their functionality is
optimal and not may present a problematic situation
(Herrera R et al., 2011).
Once the improvements have been developed,
the changes that allow visualizing the increases in the
induces of productivity, quality and quantity of
manufactured products can be observed, in addition to
avoiding an accident or work-related illness. In order to
implement the improvements with the Kaizen tool,
specific and real goals must be established for each
stage of the industry process, thoroughly analyzing each
activity and developing an optimization plan that
generates benefits quickly. One might think that once
the improvements are made in each stage of the
industrial process, the solutions will be obtained
immediately, but sometimes an improvement must be
evaluated for a certain amount of time until it stabilizes
and thus the benefits of its application are reflected.
Figure 2 shows the information of the Kanban and
Kaizen tools (Fortuny J et al., 2008).

Figure 2: Representations of Kanban and Kaizen for the development of continuous improvement
Source (a): https://www.accuratereviews.com/kanban-meaning-and-how-it-works/
Source (b): https://www.kanbanchi.com/what-is-kaizen

Beer Industry
It is a relevant type of industry in the countries
where it is developed, being an important factor in the
Gross Domestic Product (GDP), due to its large amount
of demand for manufactured products and the enormous
generation of sales, as it is a product consumed by
various social classes. In the Republic of Mexico there
are two main global brand companies, being Grupo
Modelo and Grupo Heineken Mexico (previously called
Cervecería Cuauhtémoc Moctezuma), and others on a
smaller scale with respect to the amount of products
manufactured and sales (ACERMEX, 2019). In
addition, Craft beer production companies are included, Figure 3: Industrial process of a brewing company
such as the company, where this research was carried similar to that of the industry where the research
out, which is located in the city of Ensenada, Baja was made
California, in the northwest of the Mexican Republic. Source:
Figure 3 shows an industrial process of brewing beer. https://www.puntoporpunto.com/secciones/punto-de-
encuentro/cerveceras-en-mexico-continuan-en-la-
incertidumbre/
© 2021 Middle East Research Journal of Engineering and Technology | Published by Kuwait Scholars Publisher, Kuwait 30
 Elizabeth R. Samaniego et al.; Middle East Res J. Eng. Technol., Nov-Dec, 2021; 1(1): 28-35

system), forming together the so-called Information and

Communication Technologies (ICT). Figure 5 shows
how ICT interacts with industrial processes in various
Productivity and Costs types of industries.
It is an important factor of the industries that
has a great relationship between these terms and with
the production processes where economic gains or
losses can be determined. Productivity is considered an
economic measurement action, managing to calculate
goods (products manufactured in industrial companies)
and services (activities that are offered by companies
that provide services to consumers). Figure 4 represents
the balance factor of costs and benefits in industrial
companies, where productivity and costs are involved
for a better understanding of this relevant relationship
(Marin J et al., 2009).

Figure 5: Uses of ICT in industrial processes

Source: https://www.unir.net/ingenieria/revista/el-
impacto-de-la-industria-4-0-en-la-logistica-6-avances-
que-ya-revolucionan-el-sector/

Automated control systems

They are widely used in the industry to control
the activities of industrial processes, helping to a great
extent to detect weaknesses and strengths at each stage
Figure 4: Balance of costs and benefits associating
of the process to increase productivity and quality
productivity and quality in industries
levels, based on the reinforcement of automated
Source:
systems controlled by computerized teams that train
https://www.123rf.com/photo_23393212_reduce-costs-
ICT. These automated control systems include
by-increasing-quality-productivity-and-speed.html
cybernetic, electronic, electromechanical and
electropneumatic devices widely used in industrial
In productivity, certain aspects are determined
processes in any industry (Loza A et al., 2009). Figure
such as the number of workers and their skills and
6 illustrates an automated system used in an industrial
aptitudes, as well as investment capital, production
process in a brewing industry.
times, distribution and delivery to customers.
Productivity is associated with the quality factor, which
in turn is related to manufacturing costs and is a
relevant aspect in the growth or decline of industries.
The link between productivity and quality is essential
and is focused on the application of a very strict
discipline so as not to generate economic losses, which
is associated with cost analysis.

Information and communication technologies

This type of technology is based on applying
the resources and tools necessary for the development
of computer programs (software) in various activities
where industrial processes are contemplated, where
there are countless applications (Valderrama A et al.,
2011). The development of these programs is based on
Figure 6: Automated industrial process in the
the requirements specified in the characteristics of the
brewing industry using ICT
different types of industrial processes, using a
Source. https://www.eurobots.net/news/la-industria-
computerized system for the activities of analysis,
cervecera-y-el-impacto-de-los-robots-industriales/
verification, administration, control, organization and
distribution essentially; developed with technological
systems such as computers (computerized systems), METHODOLOGY
telephones and televisions, mainly (Boyd D et al., In this investigation, an experimental process
2012). These computerized equipments are was carried out that included analysis in an industrial
interconnected with networks (wired or wireless
© 2021 Middle East Research Journal of Engineering and Technology | Published by Kuwait Scholars Publisher, Kuwait 31
 Elizabeth R. Samaniego et al.; Middle East Res J. Eng. Technol., Nov-Dec, 2021; 1(1): 28-35
process of a brewing industry, considering the
following evaluations:
a) Characterization of the industrial process using
manufacturing tools such as the Value Stream Map,
Kanban and Kaizen.
b) Analysis of productivity, quality and costs.
c) Development of a prototype of an automated
electronic system controlled by a computerized
equipment using ICT.
Measuring equipment such as the Besonere
brand digital chronometer were used to evaluate the
manufacturing times of each stage of the industrial
process, made by both the personnel who operate the
equipment, machinery and industrial systems, as well as
a voltage, electric current and power meter. electrical
such as the GEN brand voltage, current and power
factor tester; to determine the types of electronic
devices used in the prototype coupled to a computerized
system.
Table 1: Analysis of the process flow distribution with the value flow map
Step Description of the step
1 Verification of the bottle in good condition made 4
up of two activities: (a) visual inspection by a
person from the operating area and (b)
inspection by means of an optical sensor
operated by an automated system
2 Placing the bottle in an area to start the filling 3
activity manually by an operative person from
the manufacturing area
3 Brewing processes with an automated system
4 Activity of filling beer in the bottles in good 5
condition by means of an automated system
5 Full bottle inspection operation, verifying the 5
filling level of the beer in the bottle by means of
visual inspection manually by an operative
person from the manufacturing area, manually
by an operative person from the manufacturing
area, and by a system automated
6 Activity of gluing the label on the bottle with 4
product made by an automated system
7 Manual packaging operation and warehouse 3
organization with operating personnel from the
manufacturing area
© 2021 Middle East Research Journal of Engineering and Technology | Published by Kuwait Scholars Publisher, Kuwait
RESULTS
The investigation generated relevant
information from the evaluations made to determine the
types of improvements to be made in the industrial
process of the brewing industry where the scientific
study was prepared and shown in the following
sections.
Characterization analysis
It was developed to detect the weaknesses and
strengths of each stage of the industrial process (being
seven stages) and explained in the analysis of the value
stream map. For the beginning of the research, the
analysis of the value flow map was carried out as the
first activity, to know the operations of the industrial
process in the brewing industry where the scientific
study was carried out and thus determine its value as
part of the manufacturing process. Table 1 shows the
activities of the industrial process and their level of
relevance.
NCP Improvement developed
In this stage, an improvement was made to verify
and control and thus achieve an optimal operation
of the automated system through ICT, obtaining
information instantly on this operation and quickly
making the necessary adjustments
There was no need for a momentary upgrade. In
the future it could be applied.
5 At this stage, an improvement was developed to
verify and control and thus achieve optimal
operation of the automated system through ICT, to
obtain information instantly on this operation and
quickly develop the necessary adjustments
En esta etapa se desarrolló una mejora para
verificar y controlar y así lograr un óptimo
funcionamiento del sistema automatizado por
medio de las TIC, para obtener información al
instante de esta operación y desarrollando
rápidamente los ajustes necesarios
At this stage, an improvement was made for
verification and control and thereby achieve
optimal operation of the automated system
through IT, obtaining information on this
operation instantly and immediately making the
required adjustments.
At this stage, an improvement was developed for
the verification and control and thereby achieves
an optimal operation of the automated system by
means of a computerized equipment using a
computer program using ICT and quickly making
the necessary adjustments.
In this stage, the Kanban and Kaizen tool was
applied for an optimal organization of the
products produced and placed in a warehouse.
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LCP-Level of complexity in the process
expressed from 1 to 5, where the higher the level, the
higher the degree of complexity.
The table above shows the stages of the
brewing process in the industry where the scientific
study was carried out, indicating the explanation of
each stage, the level of complexity of the operation and
the improvement made in each industrial operation,
except in one where At the moment it is not necessary
to carry it out and consider it as an improvement in the
near future and part of this research that is still ongoing.
It is observed in the information in the table that the
levels of complexity range from level 3 to 5 in various
stages. Figure 7 represents a flow diagram of the
industrial operations as explained in Table 1, of the
brewing company where the research was carried out.

Figure 7: Representation of the process flow distribution

Subsequently, a format was developed to apply the Kanban tool, shown in table 2, of the monitoring of the flow
of the material, by-product and final product.

Table 2: Process flow evaluation format with Kanban and Kaizen tools
Verification 1 2 3 4 5 6 7 8
Step
1
2
3
4
5
6
7
A. Indicates that the material, by-product or final product is within the quality parameters
B. Indicates that the material, by-product or final product is not in the quality parameters

Based on the developed format (which was not an evaluation was carried out in hourly, daily, weekly
available in the industrial process) and which was used periods , monthly and seasonal of the year 2020 shown
for the verifications in the industrial process during in Table 3.
each hour in eight-hour shifts from Monday to Friday,

Table 3: Process flow analysis with Kanban and Kaizen tools (2020)
Monthly Period 1 2 3 4 5 6 7 8 9 10 11 12
Step
1 A A A A A A A A A A A A
2 B A A A A A A A A A A A
3 B B A A A A A A A A A A
4 B B A A A A A A A A A A
5 B A A A A A A A A A A A
6 B B A A A A A A A A A A
7 B B A A A A A A A A A A
A. Indicates that the material, by-product or final product is within the quality parameters
B. Indicates that the material, by-product or final product is not in the quality parameters

As can be seen in Table 3, at the beginning of
the investigation there was no control of the flow of the
material, by-product and final product; therefore,
improvements (Kaizen application) were made to
organize these and place locations for each one, which
the industrial process did not have. It is shown that from
the third this aspect was controlled and with it both the
levels of productivity and quality, as well as the
quantity of manufactured products increased, reducing
operating and manufacturing costs and increasing sales
and economic profits. The numbers in the upper part
indicate the S's of the year, the month of January being
the 1st and so on until the month of December
represented by the number 12.
Evaluation of productivity, quality and costs
An analysis of the parameters of productivity,
quality and costs (represented by economics data) was
carried out; indicating their relationship in table 4.

© 2021 Middle East Research Journal of Engineering and Technology | Published by Kuwait Scholars Publisher, Kuwait 33
 Elizabeth R. Samaniego et al.; Middle East Res J. Eng. Technol., Nov-Dec, 2021; 1(1): 28-35

Table 4: Productivity, quality and cost analysis (2020)

Monthly Period 1 2 3 4 5 6 7 8 9 10 11 12
Step
1 1,3,5 2,3,5 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6
2 1,3,5 2,3,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6
3 1,3,5 1,3,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6
4 1,3,5 2,4,5 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6
5 1,3,5 1,3,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6
6 1,3,5 2,4,5 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6
7 1,3,5 2,3,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6 2,4,6
PLL (1). Productivity-Low Level, PHL (2). Productivity-High Level
CNB (3). Productivity-Low Level, CNA (4). Productivity-High Level
ENB (5). Productivity-Low Level, ENA (6). Productivity-High Level
PNB (1). Productividad-Nivel Bajo, PNA (2). Productividad-Nivel Alto
CNB (3). Productividad-Nivel Bajo, CNA (4). Productividad-Nivel Alto
ENB (5). Productividad-Nivel Bajo, ENA (6). Productividad-Nivel Alto

Table 4 illustrates the levels of productivity,
quality and costs (represented by economic data),
indicating that at the beginning of the investigation, the
levels of the parameters mentioned, where it is observed
that in the first two months of the scientific study, no
they reached the goals of productivity and quality, and
with it the quantity of elaborated products, originating
high operating costs and low sales and the presence of
economic losses. But, it was possible to stabilize the
aforementioned parameters, starting in the third month
and thus obtain high rates of productivity, quality and
quantity of manufactured products and generate low
operating costs, increased sales and economic profits.
Automated device development
An analysis was carried out to organize the
products made in the warehouse with an automated
system that generated an indicator signal when a
product was not in its corresponding place to achieve
optimal organization. The prototype proposed as an
automated detection device is represented in the form of
a block diagram in Figure 8.

Figure 8: Representation of the stages of the automated device

The system contemplates the stages
represented in figure 8, with each stage of the
automated system being explained immediately:
A. Power supply. It generates the electrical energy
necessary for the automated system to operate in
optimal conditions.
B. Product detection module in correct location using
barcode. It is a system that contains a bar detector
module, a component made up of a black space and
a blank one that together read the codes and the
component that generates the bar code characters.
C. Indicating device. It is an element that originates an
indicator signal, being in this automated system it
is a low intensity light source.
D. Peer to Peer system. Components that generate data
information by means of a signal captured from the
bar code and be sent to a single computerized
computer that stores the captured data
E. Information storage equipment. Computerized
computer that stores the data captured with the
barcode system.
CONCLUSIONS
The research carried out in a brewing industry
located in the northwest of the Mexican Republic
helped to generate the necessary improvements that will
© 2021 Middle East Research Journal of Engineering and Technology | Published by Kuwait Scholars Publisher, Kuwait
generate the control of the industrial operations of the
manufacturing area. The detailed analysis with the
manufacturing tools originated the information required
to determine what was happening in the industrial
process and thus make the pertinent improvements. The
development of the automated system supported to a
great extent to control the location of the products in the
warehouse area and not to generate confusion when
sending to the clients and to avoid claims.
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